Process of making a multi-ply fibrous water soluble product

ABSTRACT

A process for manufacturing a water soluble product including the steps of: providing a water soluble fibrous first ply; providing a water soluble fibrous second ply formed on a surface other than the first ply, wherein the second ply is separate from the first ply; superposing the first ply and the second ply; and joining a first portion of the first ply to a second portion of the second ply to form the water soluble product.

FIELD OF THE INVENTION

Multi-ply fibrous water soluble unit dose articles and process of making

BACKGROUND OF THE INVENTION

Fibrous water soluble unit dose articles are of increasing interest toconsumers. The technology related to such articles continues to advancein terms of providing the desired active agents with the articlesenabling the consumers to do the job that they wish to accomplish.

In the realm of consumer goods, delivering the right active agents isjust not enough to satisfy consumers. The look and feel of the productis often important to consumers' perceptions.

Fibrous substrates have historically been used in consumer goodsincluding dryer sheets, toilet goods, and wipes. Such products havetended to be floppy and drape around consumers' hands or fingers whenthe product is used. This can make the products difficult or unenjoyablefor consumers to handle neatly. For such products that include activeagents, it may be desirable to limit the contact between the consumer'shand and the active agents. Some fibrous substrates have a surfacetexture that some consumers find to be tactilely deficient. Further,when active agents are carried by fibrous substrates, the consumer mayfind it unpleasant to touch the active agent.

With these limitations in mind, there is a continuing unaddressed needfor processes to make fibrous water soluble unit dose articles that areacceptable to consumers.

SUMMARY OF THE INVENTION

A process for manufacturing a water soluble product comprising the stepsof: providing a water soluble fibrous first ply; providing a watersoluble fibrous second ply formed on a surface other than the first ply,wherein the second ply is separate from the first ply; superposing thefirst ply and the second ply; and joining a first portion of the firstply to a second portion of the second ply to form the water solubleproduct.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a product.

FIG. 2 is a first ply having a first layer and a second layer.

FIG. 3 a manufacturing line for making plies of material.

FIG. 4 is a second ply being joined to a first ply to form a product.

FIG. 5 is a manufacturing line for making a two-ply product.

FIG. 6 is a cross section view of a two-ply product.

FIG. 7 is a cross section view of a two-ply product, each ply being amultilayer ply.

FIG. 8 is manufacturing line for making a three-ply product.

FIG. 9 is a cross section view of a three-ply product, each ply being amultilayer ply.

DETAILED DESCRIPTION OF THE INVENTION

A water soluble product 5 is shown in FIG. 1. The water soluble product5 can comprise a water soluble fibrous first ply 10 and water solublefibrous second ply 15 that are superposed relative to one another. Thefirst ply 10 and second ply 15 are joined to one another to form aunitary water soluble product 5. The water soluble product 5 can have amass from about 50 mg to about 30 g, optionally about 100 mg to about 20g, optionally about 1 g to about 20 g. The water soluble product 5 canhave a length and width from about 5 mm to about 20 cm, optionally fromabout 1 cm to about 10 cm, and a thickness from about 1 mm to about 2cm, optionally about 2 mm to about 10 mm

For the types of water soluble fibrous plies described herein, it can bechallenging to manufacture an individual ply that is rigid enough so asnot to be floppy when the consumer uses the product. The water solubleproduct may have planar area of between about 1 cm² and about 100 cm².The stiffness of a fibrous ply can be function of thickness of the ply,the strength and stiffness of the individual fibers constituting theply, the quantity of inter-fiber bonds, the degree and nature ofentanglement of the fibers, and the strength of the inter-fiber bonds.For the fibers constituting the fibrous plies discussed herein, it canbe difficult to provide for sufficiently thick ply, having sufficientlystrong and stiff water soluble fibers, that are sufficientlyinter-bonded and entangled with one another in a desired structure, andbonded with one another such that a ply made of such fibers is notfloppy under its self-weight.

Providing a multi-ply water soluble product 5 can help to overcome theselimitations. The increased thickness of the water soluble productachieved by layering and joining plies can provide for higher in-planebending stiffness since the moment of inertia about the bending axis isincreased. Such products 5 are not as floppy as thinner single plyproducts. Further, the increased thickness of such products 5 make themeasier for the consumer to grasp and handle. Further multi-ply products5 provide for positions interior to the product where active agents canbe placed so that the consumer does not come into contact with theactive agent.

The plies of the water soluble product 5 can be viewed hierarchicallystarting from the form in which the consumer interacts with the watersoluble product 5 and working backward to the raw materials from whichthe plies are made.

I. Fibrous Plies A. Fibrous Structures

The fibrous plies can be fibrous structures. Fibrous structures compriseone or more fibrous elements. The fibrous elements can be associatedwith one another to form a structure. Fibrous structures can includeparticles within and or on the structure. Fibrous structures can behomogeneous, layered, unitary, zoned, or as otherwise desired, withdifferent active agents defining the various aforesaid portions.

A fibrous structure can comprise one or more layers, the layers togetherforming the ply. For instance, as shown in FIG. 2, the first ply 10 cancomprise a first layer 20 and a second layer 25. The first layer 20 andsecond layer 25 can comprise a plurality of fibrous elements 30. Thefirst ply 10 can comprise a plurality of particles at a locationselected from the group consisting of the first layer 20, the secondlayer 25, between the first layer 20 and second layer 25, andcombinations thereof. A ply haying a plurality of layers can be formedby depositing a plurality of fibrous elements 30 having a distinguishingcharacteristic to form a first layer 20 and then depositing a secondlayer 25 of fibrous elements 30 on top of the first layer 20. Forclarity, for multilayer plies, there can be intermingling of fibersconstituting the layers. Further, for clarity, there can beintermingling of fibers constituting the plies.

A fibrous structure can comprise a plurality of identical orsubstantially identical from a compositional perspective of fibrouselements 30. Optionally, the fibrous structure may comprise two or moredifferent fibrous elements 30. Non-limiting examples of differences inthe fibrous elements 30 may be physical differences such as differencesin diameter, length, texture, shape, rigidness, elasticity, and thelike; chemical differences such as crosslinking level, solubility,melting point, glass transition temperature, active agent,filament-forming material, color, level of active agent, basis weight,level of filament-forming material, presence of any coating on fibrouselement, biodegradable or not, hydrophobic or not, contact angle, andthe like; differences in whether the fibrous element 30 loses itsphysical structure when the fibrous element is exposed to conditions ofintended use; differences in whether the fibrous element's 30 morphologychanges when the fibrous element 30 is exposed to conditions of intendeduse; and differences in rate at which the fibrous element 30 releasesone or more of its active agents when the fibrous element 30 is exposedto conditions of intended use. In one example, two or more fibrouselements 30 and/or particles within the fibrous structure may comprisedifferent active agents.

The fibrous structure may exhibit different regions, such as differentregions of basis weight, density and/or caliper, surface texture,pattern of fibrous structure, embossing pattern, apertures, apertures ina pattern, and the like.

Non-limiting examples of use of the fibrous structure of the presentinvention include, but are not limited to a dissolvable and/or meltablesubstrate used in a washing machine, in a laundry dryer, treat a hardsurface for cleaning and/or polishing, treat a floor for cleaning and/orpolishing substrate, to treat skin, to apply insect repellant, to treatswimming pools, as a breath freshener, a deodorant, as a wound dressing,for medicine delivery, skin care substrate, hair care substrate, aircare substrate, water treatment substrate and/or filter, toilet bowlcleaning substrate, candy substrate, teeth whitening substrates, carpetcleaning substrates, and other suitable uses of the active agents of thepresent invention. The fibrous structure of the present invention may beused as is or may be coated with one or more active agents.

B. Fibrous Elements

The fibrous elements 30 may be water soluble. The fibrous elements 30can comprise constituent material selected from the group consisting ofone or more filament forming materials, one or more active agents, andcombinations thereof. The active agents may be releasable from thefibrous elements 30, such as when the fibrous element 30 and/or fibrousstructure comprising the fibrous element 30 is exposed to conditions ofintended use.

The fibrous elements can comprise from about 5% to about 100% by weighton a dry fibrous element basis and/or dry fibrous structure basis of oneor more filament-forming materials. The fibrous elements can comprisefrom about 5% to about 100% by weight on a dry fibrous element basisand/or dry fibrous structure basis of one or more filament-formingmaterials and from about 5% to about 95% by weight by weight on a dryfibrous element basis and/or dry fibrous structure basis one or moreactive agents.

The fibrous elements can comprise more than about 50% by weight on a dryfibrous element basis and/or dry fibrous structure basis of one or morefilament-forming materials and less than about 50% by weight on a dryfibrous element basis and/or dry fibrous structure basis of one or moreactive agents.

The fibrous elements can comprise less than about 50% by weight on a dryfibrous element basis and/or dry fibrous structure basis of one or morefilament-forming materials and more than about 50% by weight on a dryfibrous element basis and/or dry fibrous structure basis of one or moreactive agents.

A fibrous element 30 can comprise one or more filament-forming materialsand one or more active agents selected from the group consisting of:enzymes, bleaching agents, builder, chelants, sensates, dispersants,perfumes, antimicrobials, antibacterials, antifungals, and mixturesthereof that are releasable and/or released when the fibrous elementand/or fibrous structure comprising the fibrous element is exposed toconditions of intended use.

The fibrous elements 30 may be meltdown fibrous elements 30, spunbondfibrous elements 30, hollow fibrous elements 30, or the like. Thefibrous elements 30 may be hydrophilic or hydrophobic. The fibrouselements 30 may be surface treated and/or internally treated to changethe inherent hydrophilic or hydrophobic properties of the fibrouselement. The fibrous elements 30 can have a diameter of less than about100 μm and/or less than about 75 μm and/or less than about 50 μm and/orless than about 25 μm and/or less than about 10 μm and/or less thanabout 5 μm and/or less than about 1 μm as measured according to theDiameter Test Method described herein. The fibrous elements 30 can havea diameter from about 1μm to about 500 μm, optionally about 1 μm toabout 100 μm, optionally about 1 μm to about 50 μm, optionally about 1μm to about 30 μm, optionally about 5 μm to about 15 μm, optionallyabout 7 μm to about 15 μm according to the Diameter Test Methoddescribed herein. The fibrous elements 30 can have a diameter of greaterthan about 1 μm as measured according to the Diameter Test Methoddescribed herein. The smaller the diameter the faster the rate ofrelease of the active agents and the rate of loss and or altering of thefibrous element's 30 physical structure.

The fibrous element 30 may comprise an active agent within the fibrouselement and an active agent on an external surface of the fibrouselement 30, such as an active agent coating on the fibrous element 30.The active agent on the external surface of the fibrous element 30 maybe the same or different from the active agent present in the fibrouselement 30. If different, the active agents may be compatible orincompatible with one another.

The one or more active agents may be uniformly distributed orsubstantially uniformly distributed throughout the fibrous element 30.The active agents may be distributed as discrete regions within thefibrous element 30. The at least one active agent can be distributeduniformly or substantially uniformly throughout the fibrous element 30and at least one other active agent is distributed as one or morediscrete regions within the fibrous element 30. Optionally, at least oneactive agent is distributed as one or more discrete regions within thefibrous element 30 and at least one other active agent is distributed asone or more discrete regions different from the first discrete regionswithin the fibrous element 30.

C. Filament Forming Material

The filament-forming material is any suitable material, such as apolymer or monomers capable of producing a polymer that exhibitsproperties suitable for making a filament, such as by a spinningprocess. The filament-forming material may comprise a polarsolvent-soluble material, such as an alcohol-soluble material and/or awater-soluble material, which can be beneficial for product applicationsthat include use of water.

The filament-forming material may comprise a non-polar solvent-solublematerial.

The filament-forming material may comprise a water-soluble material andbe free (less than 5% and/or less than 3% and/or less than 1% and/or 0%by weight on a dry fibrous element basis and/or dry fibrous structurebasis) of water-insoluble materials.

The filament-forming material may comprise a polymer selected from thegroup consisting of: polymers derived from acrylic monomers such as theethylenically unsaturated carboxylic monomers and ethylenicallyunsaturated monomers, polyvinyl alcohol, polyvinylformamide,polyvinylamine, polyacrylates, polymethacrylates, copolymers of acrylicacid and methyl acrylate, polyvinylpyrrolidones, polyalkylene oxides,starch and starch derivatives, pullulan, gelatin, and cellulosederivatives (for example, hydroxypropylmethyl celluloses, methylcelluloses, carboxymethy celluloses).

The filament-forming material may comprise a polymer selected from thegroup consisting of: polyvinyl alcohol, polyvinyl alcohol derivatives,starch, starch derivatives, cellulose derivatives, hemicellulose,hemicellulose derivatives, proteins, sodium alginate, hydroxypropylmethylcellulose, chitosan, chitosan derivatives, polyethylene glycol,tetramethylene ether glycol, polyvinyl pyrrolidone, hydroxymethylcellulose, hydroxyethyl cellulose, carboxymethyl cellulose, and mixturesthereof.

The filament-forming material may comprise a polymer selected from thegroup consisting of: pullulan, hydroxypropylmethyl cellulose,hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl pyrrolidone,carboxymethylcellulose, sodium alginate, xanthan gum, tragacanth gum,guar gum, acacia gum, Arabic gum, polyacrylic acid, methylmethacrylatecopolymer, carboxyvinyl polymer, dextrin, pectin, chitin, levan,elsinan, collagen, gelatin, zein, gluten, soy protein, casein, polyvinylalcohol, carboxylated polyvinyl alcohol, sulfonated polyvinyl alcohol,starch, starch derivatives, hemicellulose, hemicellulose derivatives,proteins, chitosan, chitosan derivatives, polyethylene glycol,tetramethylene ether glycol, hydroxymethyl cellulose, and mixturesthereof.

1. Water-Soluble Materials

Non-limiting examples of water-soluble materials include water-solublepolymers. The water-soluble polymers may be synthetic or naturaloriginal and may be chemically and/or physically modified.

Non-limiting examples of water-soluble polymers include water-solublehydroxyl polymers, water-soluble thermoplastic polymers, water-solublebiodegradable polymers, water-soluble non-biodegradable polymers andmixtures thereof. The water-soluble polymer may comprise polyvinylalcohol. In another example, the water-soluble polymer may comprisestarch. The water-soluble polymer may comprise polyvinyl alcohol andstarch. The water-soluble polymer may comprise carboxymethyl cellulose.The polymer may comprise carboxymethyl cellulose and polyvinyl alcohol.

a. Water-Soluble Hydroxyl Polymers

Non-limiting examples of water-soluble hydroxyl polymers in accordancewith the present invention can be selected from the group consisting ofpolyols, such as polyvinyl alcohol, polyvinyl alcohol derivatives,polyvinyl alcohol copolymers, starch, starch derivatives, starchcopolymers, chitosan, chitosan derivatives, chitosan copolymers,cellulose derivatives such as cellulose ether and ester derivatives,cellulose copolymers, hemicellulose, hemicellulose derivatives,hemicellulose copolymers, gums, arabinans, galactans, proteins,carboxymethylcellulose, and various other polysaccharides and mixturesthereof.

Polyvinyl alcohols herein can be grafted with other monomers to modifyits properties. A wide range of monomers has been successfully graftedto polyvinyl alcohol. Non-limiting examples of such monomers includevinyl acetate, styrene, acrylamide, acrylic acid, hydroxyethylmethacrylate. acrylonitrile, 1,3-butadiene, methyl methacrylate,methacrylic acid, maleic acid, itaconic acid, sodium vinylsulfonate,sodium allylsulfonate, sodium methylallyl sulfonate, sodiumphenylallylether sulfonate, sodium phenylmethallylether sulfonate,2-acrylamide-methyl propane sulfonic acid (AMPs), vinylidene chloride,vinyl chloride, vinyl amine and a variety of acrylate esters.

In one example, the water-soluble hydroxyl polymer is selected from thegroup consisting of: polyvinyl alcohols, hydroxymethylcelluloses,hydroxyethylcelluloses, hydroxypropylmethylcelluloses,carboxymethylcelluloses, and mixtures thereof. A non-limiting example ofa suitable polyvinyl alcohol includes those commercially available fromSekisui Specialty Chemicals America, LLC (Dallas, Tex.) under the CELVOL(Registered trademark) trade name. Another non-limiting example of asuitable polyvinyl alcohol includes G Polymer commercially availablefrom. Nippon Ghosei. A non-limiting example of a suitable hydroxypropylmethylcellulose includes those commercially available from the.Dow Chemical Company (Midland, Mich.) under the METHOCEL (Registeredtrademark) trade name including combinations with above mentionedpolyvinyl alcohols.

b. Water-Soluble Thermoplastic Polymers

Non-limiting examples of suitable water-soluble thermoplastic polymersinclude thermoplastic starch and/or starch derivatives, polylactic acid,polyhydroxyalkanoate, polycaprolactone, polyesteramides and certainpolyesters, and mixtures thereof. The water-soluble thermoplasticpolymers may be hydrophilic or hydrophobic. The water-solublethermoplastic polymers may be surface treated and/or internally treatedto change the inherent hydrophilic or hydrophobic properties of thethermoplastic polymer. The water-soluble thermoplastic polymers maycomprise biodegradable polymers. Any suitable weight average molecularweight for the thermoplastic polymers may be used. For example, theweight average molecular weight for a thermoplastic polymer inaccordance with the present invention can be greater than about 10,000g/mol and/or greater than about 40,000 g/mol and/or greater than about50,000 g/mol and/or less than about 500,000 g/mol and/or less than about400,000 g/mol and/or less than about 200,000 g/mol.

D. Active Agents

Active agents are a class of additives that are designed and intended toprovide a benefit to something other than the fibrous element and/orparticle and/or fibrous structure itself, such as providing a benefit toan environment external to the fibrous element and/or particle and/orfibrous structure. The active agent may be selected from the groupconsisting of: personal cleansing and/or conditioning agents such ashair care agents such as shampoo agents and/or hair colorant agents,hair conditioning agents, skin care agents, sunscreen agents, and skinconditioning agents; laundry care and/or conditioning agents such asfabric care agents, fabric conditioning agents, fabric softening agents,fabric anti-wrinkling agents, fabric care anti-static agents, fabriccare stain removal agents, soil release agents, dispersing agents, sudssuppressing agents, suds boosting agents, anti-foam agents, and fabricrefreshing agents; liquid and/or powder dishwashing agents (for handdishwashing and/or automatic dishwashing machine applications), hardsurface care agents, and/or conditioning agents and/or polishing agents;other cleaning and/or conditioning agents such as antimicrobial agents,antibacterial agents, antifungal agents, fabric hoeing agents, perfume,bleaching agents (such as oxygen bleaching agents, hydrogen peroxide,percarbonate bleaching agents, perborate bleaching agents, chlorinebleaching agents), bleach activating agents, chelating agents, builders,lotions, brightening agents, air care agents, carpet care agents, dyetransfer-inhibiting agents, clay soil removing agents, anti-redepositionagents, polymeric soil release agents, polymeric dispersing agents,alkoxylated polyamine polymers, alkoxylated polycarboxylate polymers,amphilic graft copolymers, dissolution aids, buffering systems,water-softening agents, water-hardening agents, pH adjusting agents,enzymes, flocculating agents, effervescent agents, preservatives,cosmetic agents, make-up removal agents, lathering agents, depositionaid agents, coacervate-forming agents, clays, thickening agents,latexes, silicas, drying agents, odor control agents, antiperspirantagents, cooling agents, warming agents, absorbent gel agents,anti-inflammatory agents, dyes, pigments, acids, and bases; liquidtreatment active agents; agricultural active agents; industrial activeagents; ingestible active agents such as medicinal agents, teethwhitening agents, tooth care agents, mouthwash agents, periodontal gumcare agents, edible agents, dietary agents, vitamins, minerals;water-treatment agents such as water clarifying and/or waterdisinfecting agents, and mixtures thereof.

1. Surfactants

Non-limiting examples of suitable surfactants include anionicsurfactants, cationic surfactants, nonionic surfactants, zwitterionicsurfactants, amphoteric surfactants, and mixtures thereof.Co-surfactants may also be included in the fibrous elements and/orparticles. For fibrous elements and/or particles designed for use aslaundry detergents and/or dishwashing detergents, the total level ofsurfactants should be sufficient to provide cleaning including stainand/or odor removal, and generally ranges from about 0.5% to about 95%.Further, surfactant systems comprising two or more surfactants that aredesigned for use in fibrous elements and/or particles for laundrydetergents and/or dishwashing detergents may include all-anionicsurfactant systems, mixed-type surfactant systems comprisinganionic-nonionic surfactant mixtures, or nonionic-cationic surfactantmixtures or low-foaming nonionic surfactants. The surfactants herein canbe linear or branched. In one example, suitable linear surfactantsinclude those derived from agrochemical oils such as coconut oil, palmkernel oil, soybean oil, or other vegetable-based oils.

2. Perfumes

One or more perfume and/or perfume raw materials such as accords and/ornotes may be incorporated into one or more of the fibrous elementsand/or particles of the present invention. The perfume may comprise aperfume ingredient selected from the group consisting of: aldehydeperfume ingredients, ketone perfume ingredients, esters, and mixturesthereof. Also included are various natural extracts and essences whichcan comprise complex mixtures of ingredients, such as orange oil, lemonoil, rose extract, lavender, musk, patchouli, balsamic essence,sandalwood oil, pine oil, cedar, and the like. In one example, afinished perfume typically comprises from about 0.01% to about 2% byweight on a dry fibrous element basis and/or a dry particle basis and/ordry fibrous structure basis.

The perfume can be delivered by a perfume delivery system. The perfumedelivery system can be a polymer assisted delivery system. This perfumedelivery technology uses polymeric materials to deliver perfumematerials. Classical coacervation, water soluble or partly soluble toinsoluble charged or neutral polymers, liquid crystals, hot melts,hydrogels, perfumed plastics, encapsulated perfume, nano- andmicro-latexes, polymeric film formers, and polymeric absorbents,polymeric adsorbents, etc. are some examples. The polymer assisteddelivery system can be a matrix system in which the fragrance isdissolved or dispersed in a polymer matrix or particle.

The perfume delivery system can be an encapsulate. Encapsulated perfumescomprise a core that is the perfume and a shell that is the encapsulatewall. The encapsulate can be a pressure sensitive encapsulate.

The perfume delivery system can be a fiber assisted delivery system. Theperfume can be loaded and or stored on the surface of the fiber orabsorbed into the fiber. When used, the perfume can be released from thefiber.

The perfume delivery system can be an amine assisted delivery system.Amine assisted delivery systems can comprise a material that has anamine group to increase perfume deposition and or modify perfume releaseduring product use. Amine assisted delivery system materials suitablefor use herein may be non-aromatic; for example, polyalkylimine, such aspolyethyleneimine (PEI), or polyvinylamine (PVAm), or aromatic, forexample, anthranilates. Such materials may also be polymeric ornon-polymeric. In one aspect, such materials contain at least oneprimary amine.

The perfume delivery system can be a cyclodextrin delivery system. Thistechnology approach uses a cyclic oligosaccharide or cyclodextrin toimprove the delivery of perfume. Typically, a perfume and cyclodextrincomplex is formed.

The perfume delivery system can be a starch encapsulated accord. Thistechnology employs liquid perfume converted to a solid by addingingredients such as starch.

The perfume delivery system can be an inorganic carrier delivery system.In such a system, perfume is loaded onto an inorganic carrier, forexample zeolite, porous zeolite, or other inorganic material.

The perfume delivery system can be a pro perfume. This technologycomprises a perfume covalently bonded to a carrier. The pro perfume canbe an amine reaction product. That is, a polymeric amine reacted withone or more perfume raw material to form the amine reaction product.

3. Antimicrobials, Antibacterials, and Antifungals

The active agent can be selected from the group consisting of an antiantibacterial, antifungal, and combinations thereof.

4. Bleaching Agent

The fibrous elements and or particles of the present invention maycomprise one or bleaching agents. Non-limiting examples of suitablebleaching agents include peroxyacids, perborate, percarbonate, chlorinebleaches, peroxygen bleach, percarboxylic acid bleach and salts thereof,oxygen bleaches, persulfate bleach, hypohalite bleaches, bleachprecursors, bleach activators, bleach catalysts, hydrogen peroxide,bleach boosters, photobleaches, bleaching enzymes, free radicalinitiators, peroxygen bleaches, and mixtures thereof.

One or more bleaching agents may be included in the fibrous elementsand/or particles of the present invention may be included at a levelfrom about 0.05% to about 30% and/or from about 1% to about 20% byweight on a dry fibrous element basis and/or dry particle basis and/ordry fibrous structure basis. If present, bleach activators may bepresent in the fibrous elements and/or particles of the presentinvention at a level from about 0.1% to about 60% and/or from about 0.5%to about 40% by weight on a dry fibrous element basis and/or dryparticle basis and/or dry fibrous structure basis.

5. Dye Transfer Inhibiting Agent

The fibrous elements and/or particles may include one or more dyetransfer inhibiting agents. Suitable polymeric dye transfer inhibitingagents include, but are not limited to, polyvinylpyrrolidone polymers,polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone andN-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles ormixtures thereof. The dye transfer inhibiting agents may be present inthe fibrous elements and/or particles and/or fibrous structure productsof the present invention at levels from about 0.0001% to about 10%, fromabout 0.01% to about 5% or even from about 0.1% to about 3% by weight ona dry fibrous element basis and/or dry particle basis and/or dry fibrousstructure basis.

6. Brighteners

The fibrous elements and/or particles of the present invention maycontain active agents, such as brighteners, for example fluorescentbrighteners. Such brighteners may tint articles being cleaned. Thefibrous elements and/or particles may comprise C.I. fluorescentbrightener 260 in alpha-crystalline form.

7. Hueing Agents

The composition may comprise a hueing agent. Suitable hueing agentsinclude dyes, dye-clay conjugates, and pigments. Suitable dyes includesmall molecule dyes and polymeric dyes. Suitable small molecule dyesinclude small molecule dyes selected from the group consisting of dyesfalling into the Colour Index (C.I.) classifications of Direct Blue,Direct Red, Direct Violet, Acid Blue, Acid Red, Acid Violet, Basic Blue,Basic Violet and Basic Red, or mixtures thereof.

In another aspect, suitable small molecule dyes include small moleculedyes selected from the group consisting of Colour Index (Society ofDyers and Colourists, Bradford, UK) numbers Direct Violet 9, DirectViolet 35, Direct Violet 48, Direct Violet 51, Direct Violet 66, DirectViolet 99, Direct Blue 1, Direct Blue 71, Direct Blue 80, Direct Blue279, Acid Red 17, Acid Red 73, Acid Red 88, Acid Red 150, Acid Violet15, Acid Violet 17, Acid Violet 24, Acid Violet 43, Acid Red 52, AcidViolet 49, Acid Violet 50, Acid Blue 15, Acid Blue 17, Acid Blue 25,Acid Blue 29, Acid Blue 40, Acid Blue 45, Acid Blue 75, Acid Blue 80,Acid Blue 83, Acid Blue 90 and Acid Blue 113, Acid Black 1, Basic Violet1, Basic Violet 3, Basic Violet 4, Basic Violet 10, Basic Violet 35,Basic Blue 3, Basic Blue 16, Basic Blue 22, Basic Blue 47, Basic Blue66, Basic Blue 75, Basic Blue 159 and mixtures thereof. In anotheraspect, suitable small molecule dyes include small molecule dyesselected from the group consisting of Colour Index (Society of Dyers andColourists, Bradford, UK) numbers Acid Violet 17, Acid Violet 43, AcidRed 52, Acid Red 73, Acid Red 88, Acid Red 150, Acid Blue 25, Acid Blue29, Acid Blue 45, Acid Blue 113, Acid Black 1, Direct Blue 1, DirectBlue 71, Direct Violet 51 and mixtures thereof. In another aspect,suitable small molecule dyes include small molecule dyes selected fromthe group consisting of Colour Index (Society of Dyers and Colourists,Bradford, UK) numbers Acid Violet 17, Direct Blue 71, Direct Violet 51,Direct Blue 1, Acid Red 88, Acid Red 150, Acid Blue 29, Acid Blue 113 ormixtures thereof.

The active agent may be pigment, Suitable pigments can include pigmentsselected from the group consisting of flavanthrone, indanthrone,chlorinated indanthrone containing from 1 to 4 chlorine atoms,pyranthrone, dichloropyranthrone, monobromodichloropyranthrone,dibromodichloropyranthrone, tetrabromopyranthrone,perylene-3,4,9,10-tetracarboxylic acid diimide, wherein the imide groupsmay be unsubstituted or substituted by C1-C3-alkyl or a phenyl orheterocyclic radical, and wherein the phenyl and heterocyclic radicalsmay additionally carry substituents which do not confer solubility inwater, anthrapyrimidinecarboxylic acid amides, violanthrone,isoviolanthrone, dioxazine pigments, copper phthalocyanine which maycontain up to 2 chlorine atoms per molecule, polychloro-copperphthalocyanine or polybromochloro-copper phthalocyanine containing up to14 bromine atoms per molecule and mixtures thereof.

Suitable pigments include pigments selected from the group consisting ofUltramarine Blue (C.I. Pigment Blue 29), Ultramarine Violet (C.I.Pigment Violet 15) and mixtures thereof.

8. Enzymes

One or more enzymes may be present in the fibrous elements and/orparticles of the present invention. Non-limiting examples of suitableenzymes include proteases, amylases, lipases, cellulases, carbohydrasesincluding mannanases and endoglucanases, pectinases, hemicellulases,peroxidases, xylanases, phospholipases, esterases, cutinases,keratanases, reductases, oxidases, phenoloxidases, lipoxygenases,ligninases, pullulanases, tannases, penosanases, malanases, glucanases,arabinosidases, hyaluraonidases, chrondroitinases, laccases, andmixtures thereof.

When present in the fibrous elements and/or particles of the presentinvention, the enzymes may be present at levels sufficient to provide a“cleaning-effective amount”. The term “cleaning effective amount” refersto any amount capable of producing a cleaning, stain removal, soilremoval, whitening, deodorizing, or freshness improving effect onsubstrates such as fabrics, dishware, flooring, porcelain and ceramics,metal surfaces and the like. In practical terms for current commercialpreparations, typical amounts are up to about 5 mg by weight, moretypically 0.01 mg to 3 mg, of active enzyme per gram of the fibrouselement and/or particle of the present invention. Stated otherwise, thefibrous elements and/or particles of the present invention willtypically comprise from about 0.001% to about 5% and/or from about 0.01%to about 3% and/or from about 0.01% to about 1% by weight on a dryfibrous element basis and/or dry particle basis and/or dry fibrousstructure basis.

One or more enzymes may be applied to the fibrous element and/orparticle after the fibrous element and/or particle is produced.

When enzymes are present in the fibrous elements and/or particles of thepresent invention, an enzyme stabilizing system may also be included inthe fibrous elements and/or particles. Enzymes may be stabilized byvarious techniques.

9. Heat Forming Agents

The fibrous elements and/or particles of the present invention maycontain a heat forming agent. Heat forming agents are formulated togenerate heat in the presence of water and/or oxygen (e.g., oxygen inthe air, etc.) and to thereby accelerate the rate at which the fibrousstructure degrades in the presence of water and/or oxygen, and/or toincrease the effectiveness of one or more of the actives in the fibrouselement. The heat forming agent can be used to accelerate the rate ofrelease of one or more actives from the fibrous structure. The heatforming agent can be formulated to undergo an exothermic reaction whenexposed to oxygen (i.e., oxygen in the air, oxygen in the water, etc.)and/or water. Non-limiting heat forming agents that can be used in thefibrous structure include electrolyte salts (e.g., aluminum chloride,calcium chloride, calcium sulfate, cupric chloride, cuprous chloride,ferric sulfate, magnesium chloride, magnesium sulfate, manganesechloride, manganese sulfate, potassium chloride, potassium sulfate,sodium acetate, sodium chloride, sodium carbonate, sodium sulfate,etc.), glycols (e.g., propylene glycol, dipropyleneglycol, etc.), lime(e.g., quick lime, slaked lime, etc.), metals (e.g., chromium, copper,iron, magnesium, manganese, etc.), metal oxides (e.g., aluminum oxide,iron oxide, etc.), polyalkyleneamine, polyalkyleneimine, polyvinylamine, zeolites, glycerin, 1,3, propanediol, polysorbates esters (e.g.,Tweens 20, 60, 85, 80), and/or poly glycerol esters (e.g., Noobe,Drewpol and Drewmulze from Stepan). The heat forming agent can be formedof one or more materials. For example, magnesium sulfate can singularlyform the heat forming agent. In another non-limiting example, thecombination of about 2-25 weight percent activated carbon, about 30-70weight percent iron powder and about 1-10 weight percent metal salt canform the heat forming agent. As can be appreciated, other or additionalmaterials can be used alone or in combination with other materials toform the heat forming agent.

10. Degrading Accelerator

The fibrous elements and/or particles of the present invention maycontain a degrading accelerator to accelerate the rate at which afibrous structure degrades in the presence of water and/or oxygen. Thedegrading accelerator, when used, is generally designed to release gaswhen exposed to water and/or oxygen, which in turn agitates the regionabout the fibrous structure to cause acceleration in the degradation ofa carrier film of the fibrous structure. The degrading accelerator, whenused, can also or alternatively be used to accelerate the rate ofrelease of one or more actives from the fibrous structure. The degradingaccelerator can include one or more materials such as, but not limitedto, alkali metal carbonates (e.g. sodium carbonate, potassium carbonate,etc.), alkali metal hydrogen carbonates (e.g., sodium hydrogencarbonate, potassium hydrogen carbonate, etc.), ammonium carbonate, etc.Non-limiting examples of activators, when used, that can be included inthe fibrous structure include organic acids (e.g., hydroxy-carboxylicacids [citric acid, tartaric acid, malic acid, lactic acid, gluconicacid, etc.], saturated aliphatic carboxylic acids [acetic acid, succinicacid, etc.], unsaturated aliphatic carboxylic acids [e.g., fumaric acid,etc.].

E. Release of Active Agents

One or more active agents may be released from the fibrous elementand/or particle and/or fibrous structure when the fibrous element and/orparticle and/or fibrous structure is exposed to a triggering condition.The active agents may be released from the fibrous element and orfibrous structure or part thereof loses its physical structure (e.g.dissolves, melts), alters its physical structure (e.g swells, shrinks,lengthens, shortens). The active agents may be released may be releasedwhen the fibrous structure or part thereof changes in morphology.

The fibrous element and/or particle and/or fibrous structure may releasean active agent upon the fibrous element and/or particle and/or fibrousstructure being exposed to a triggering condition that results in therelease of the active agent, such as by causing the fibrous elementand/or particle and/or fibrous structure to lose or alter its identityas discussed above. Non-limiting examples of triggering conditionsinclude exposing the fibrous element and/or particle and/or fibrousstructure to solvent, a polar solvent, such as alcohol and/or water,and/or a non-polar solvent, which may be sequential, depending uponwhether the filament-forming material comprises a polar solvent-solublematerial and/or a non-polar solvent-soluble material; exposing thefibrous element and/or particle and/or fibrous structure to heat and orfriction, and or pre-treating stains on a fabric article with thefibrous structure product, forming a wash liquor by contacting thefibrous structure product with water; tumbling the fibrous structureproduct in a dryer; heating the fibrous structure product in a dryer,and combinations thereof.

F. Filament-Forming Composition

The fibrous elements 30 of the present invention are made from afilament-forming composition. The filament-forming composition can be apolar-solvent-based composition. in one example, the filament-formingcomposition is an aqueous composition comprising one or morefilament-forming materials and one or more active agents. Thefilament-forming composition of the present invention may have a shearviscosity as measured according to the Shear Viscosity Test Methoddescribed herein of from about 1 Pascal.Seconds to about 25Pascal.Seconds and/or from about 2 Pascal.Seconds to about 20Pascal.Seconds and/or from about 3 Pascal.Seconds to about 10Pascal.Seconds, as measured at a shear rate of 3,000 sec-1 and at theprocessing temperature (50 deg. C. to 100 deg. C.). The filament-formingcomposition may be processed at a temperature of from about 25 deg. C.to about 100 deg. C. and/or from about 65 deg. C. to about 95 deg. C.and/or from about 70 deg. C. to about 90 deg. C. when making fibrouselements 30 from the filament-forming composition.

In one example, the filament-forming composition may comprise at least20% and/or at least 30% and/or at least 40% and/or at least 45% and/orat least 50% to about 90% and/or to about 85% and/or to about 80% and/orto about 75% by weight of one or more filament-forming materials, one ormore active agents, and mixtures thereof. The filament-formingcomposition may comprise from about 10% to about 80% by weight of apolar solvent, such as water.

In a fibrous element spinning process, the fibrous elements 30 need tohave initial stability as they leave the spinning die. Capillary numberis used to characterize this initial stability criterion. At theconditions of the die, the capillary number can be from about 0.5 toabout 10, at least 1 and/or at least 3 and/or at least 4 and/or at least5.

In one example, the filament-forming composition exhibits a capillarynumber of from about 1 to about 50 and/or about 3 to about 50 and/orabout 5 to about 30 and/or about 0.5 to about 20 and/or about 9 to about15 and/or about 15 to about 20 such that the filament-formingcomposition can be effectively polymer processed into a fibrous element.

“Polymer processing” as used herein means any spinning operation and/orspinning process by which a fibrous element comprising a processedfilament-forming material is formed from a filament-forming composition.The spinning operation and/or process may include spunbonding, meltblowing, electro-spinning, rotary spinning, continuous filamentproducing and/or tow fiber producing operations/processes. A “processedfilament-forming material” as used herein means any filament-formingmaterial that has undergone a melt processing operation and a subsequentpolymer processing operation resulting in a fibrous element.

The capillary number is a dimensionless number used to characterize thelikelihood of this droplet breakup. A larger capillary number indicatesgreater fluid stability upon exiting the die. The capillary number,c_(a), is defined as follows:

$c_{a} = \frac{V\; \eta}{\sigma}$

Where V is the average fluid velocity at the die exit (units of Lengthper Time), is the fluid viscosity at the conditions of the exit of thedie (units of Mass per Length*Time), σ is the surface tension of thefluid (units of Mass per Time²).

In one example, the filament-forming composition may comprise one ormore release agents and/or lubricants. Non-limiting examples of suitablerelease agents and/or lubricants include fatty acids, fatty acid salts,fatty alcohols, fatty esters, sulfonated fatty acid esters, fatty amineacetates and fatty amides, silicones, aminosilicones, fluoropolymers andmixtures thereof.

In one example, the filament-forming composition may comprise one ormore antiblocking and/or detackifying agents. Non-limiting examples ofsuitable antiblocking and/or detackifying agents include starches,modified starches, crosslinked polyvinylpyrrolidone, crosslinkedcellulose, microcrystalline cellulose, silica, metallic oxides, calciumcarbonate, talc and mica.

Active agents of the present invention may be added to thefilament-forming composition prior to and/or during fibrous elementformation and/or may be added to the fibrous element after fibrouselement formation. For example, a perfume active agent may be applied tothe fibrous element and/or fibrous structure comprising the fibrouselement after the fibrous element and/or fibrous structure according tothe present invention are formed. In another example, an enzyme activeagent may be applied to the fibrous element and/or fibrous structurecomprising the fibrous element after the fibrous element and/or fibrousstructure according to the present invention are formed. In stillanother example, one or more particles, which may not be suitable forpassing through the spinning process for making the fibrous element, maybe applied to the fibrous element and/or fibrous structure comprisingthe fibrous element after the fibrous element and/or fibrous structureaccording to the present invention are formed.

G. Extensional Aids

In one example, the fibrous element comprises an extensional aid.Non-limiting examples of extensional aids can include polymers, otherextensional aids, and combinations thereof. High molecular weightextensional aids can be used since they have the ability to increaseextensional melt viscosity and reduce melt fracture.

The extensional aid, when used in a meltblowing process, is added to thecomposition of the present invention in an amount effective to visiblyreduce the melt fracture and capillary breakage of fibers during thespinning process such that substantially continuous fibers havingrelatively consistent diameter can be melt spun. The extensional aidscan be present from about 0.001% to about 10%, by weight on a dryfibrous element basis and/or dry particle basis and/or dry fibrousstructure basis, in one example, and in another example from about 0.005to about 5%, by weight on a dry fibrous element basis and/or dryparticle basis and/or dry fibrous structure basis, in yet anotherexample from about 0.01 to about 1%, by weight on a dry fibrous elementbasis and/or dry particle basis and/or dry fibrous structure basis, andin another example from about 0.05% to about 0.5%, by weight on a dryfibrous element basis and/or dry particle basis and/or dry fibrousstructure basis.

Non-limiting examples of polymers that can be used as extensional aidscan include alginates, carrageenans, pectin, chitin, guar gum, xanthumgum, agar, gum arabic, karaya gum, tragacanth gum, locust bean gum,alkylcellulose, hydroxyalkylcellulose, carboxyalkylcellulose, andmixtures thereof. Nonlimiting examples of other extensional aids caninclude modified and unmodified polyacrylamide, polyacrylic acid,polymethacrylic acid, polyvinyl alcohol, polyvinylacetate,polyvinylpyrrolidone, polyethylene vinyl acetate, polyethyleneimine,polyamides, polyalkylene oxides including polyethyleneoxide,polypropylene oxide, polyethylenepropylene oxide, and mixturesthereof.

H. Method for Making Fibrous Elements and Plies

The fibrous elements 30 and plies formed therefrom may be made by anysuitable process. A non limiting example of a suitable process formaking the plies and continuous ply webs is shown in FIG. 3. A solutionof a filament forming composition 35 is provided. The filament formingcomposition can comprise one or more filament forming materials andoptionally one or more active agents. The filament forming composition35 is passed through one or more die block assemblies 40 comprising aplurality of spinnerets 45 to form a plurality of fibrous elements 30comprising the one or more filament forming materials and optionally oneor more active agents. Multiple (lie block assemblies 40 can be employedto spin different layers of fibrous elements 30, with the fibrouselements 30 of different layers having a composition that differ fromone another or are the same as one another. That is, the filamentforming composition 35 provided to one die block assembly 40 can differcompositionally from the filament forming composition 35 provided toanother die block assembly 40. More than two die block assemblies inseries can be provided to form three, four, or any other integer numberof layers in a given ply.

The fibrous elements 30 can be deposited on a belt 50 moving in amachine direction MD to form a first ply 10. The belt 50 can be aforaminous belt.

Belts 50 that are air permeable are desirable so that vacuum can beapplied to and through the belt. The belt 50 can be a XBE2A9 beltavailable from F.N. Sheppard & Co. Erlanger, Ky., USA. The belt 50 canbe formed from polyester strands or other polymeric strands. It isdesirable that the belt 50 have small openings so that the web carriedthereon is not deformed into the openings. The belt 50 can be coated tolower the surface tension of the belt 50 with respect to the web carriedthereon. The belt 50 can move at a speed from about 1 m/min to about 100m/min, optionally about 2 m/min to about 30 m/min.

The motive force to move the continuous ply webs disclosed herein may beprovide by one or more belts 50. As the belt 50 moves the continuous plywebs ride directly or indirectly through another material, for exampleanother continuous ply web, on the belt 50. For locations at which thecontinuous ply web are not in contact with a belt 50, tensile forcemobilized in the continuous ply web downstream of the location at whichthe continuous ply web loses contact with the belt 50 can pull thecontinuous ply web along. Optionally, when a continuous ply web is offof the belt, motive force can be provided by motorized rollers.

The spinnerets 45 may comprise a plurality of fibrous element-formingholes that include a melt capillary encircled by a concentricattenuation fluid hole through which a fluid, such as air at atemperature from about 10 C to about 100 C, can pass to facilitateattenuation of the filament-forming composition 35 into a fibrouselement 30 as it exits the fibrous element-forming hole. Thefilament-forming composition can be provided to the fibrous-elementforming hole at a rate of about 0.1 to about 2 g/min per hole, which canbe set based on the composition of the filament-forming composition.

During the spinning step, volatile solvent, such as water, present inthe filament-forming composition 35 can be removed, such as by drying,as the fibrous element 30 is formed. Greater than 30% and/or greaterthan 40% and/or greater than 50%, and/or greater than 60% of the weightof the filament-forming composition's volatile solvent, such as water,can be removed during the spinning step, such as by drying the fibrouselement being produced.

The filament-forming composition is spun into one or more fibrouselements 30 and/or particles by any suitable spinning process, such asmeltblowing, spunbonding, electro-spinning, and/or rotary spinning. Inone example, the filament-forming composition is spun into a pluralityof fibrous elements 30 and/or particles by meltblowing. For example, thefilament-forming composition may be pumped from a tank to a meltblownspinnerette. Upon exiting one or more of the filament-forming holes inthe spinnerette, the filament-forming composition is attenuated with airto create one or more fibrous elements 30 and/or particles. The fibrouselements 30 and/or particles may then be dried to remove any remainingsolvent used for spinning, such as the water.

The fibrous elements 30 and/or particles of the present invention may becollected on a belt, such as a patterned belt or flat belt, to form afibrous structure comprising the fibrous elements 30 and/or particlesthat are directed into the fibrous elements 30.

Particles can be introduced into the stream of the fibrous elements 30between the die block assembly 40 and the belt 50. Particles can be fedfrom a particle receiver onto a belt feeder 41 or optionally a screwfeeder. The belt feeder 41 can be set and controlled to deliver thedesired mass of particles into the process. The belt feeder can feed anair knife 42 that suspends and directs the particles in an air streaminto the fibrous elements 30 to form a mixture of comingled fibrouselements 30 and particles that are subsequently deposited on the belt50. Optionally, the particles can be homogeneously distributed in a plyor a layer of layer of a ply. The particles can be homogeneouslydistributed in the cross direction of the parent continuous ply web.Optionally, particles can be introduced after the fibrous elements 30are deposited on the belt 50. Optionally, the particles can beintroduced by gravity and or optionally in between streams offilament-forming composition. An air laid forming head or sifter can beused to introduce the particles.

Multi-layer plies can be formed by providing two die block assemblies40, one die block assembly 40 downstream of another die block assembly40, by way of nonlimiting example as shown in FIG. 3.

A pressurized tank suitable for batch operation can be filled with asuitable filament-forming composition 35 for spinning. A pump, such as aZENITH, type PEP II, having a capacity of 5.0 cubic centimeters perrevolution (cc/rev), manufactured by Parker Hannifin Corporation, ZenithPumps division, of Sanford, N.C., USA may be used to facilitatetransport of the filament-forming composition 35 to the spinnerets 45.

The die block assembly 40 can have several rows of circular extrusionnozzles (fibrous element-forming holes) spaced from one another at apitch P of about 1.524 millimeters. The nozzles can have individualinner diameters of about 0.305 millimeters and individual outsidediameters of about 0.813 millimeters. Each individual nozzle can beencircled by an annular and divergently flared orifice (concentricattenuation fluid hole to supply attenuation air to each individual meltcapillary). The filament-forming composition 35 extruded through thenozzles can be surrounded and attenuated by generally cylindrical,humidified air streams supplied through the orifices.

Attenuation air can be provided by heating compressed air from a sourceby an electrical-resistance heater, for example, a heater manufacturedby Chromalox, Division of Emerson Electric, of Pittsburgh, Pa., USA. Anappropriate quantity of steam can be added to saturate or nearlysaturate the heated air at the conditions in the electrically heated,thermostatically controlled delivery pipe. Condensate can be removed inan electrically heated, thermostatically controlled, separator.

The embryonic fibrous elements 30 can be dried by a drying air streamhaving temperature from about 149 C to about 315 C by an electricalresistance heater supplied through drying nozzles and discharged at anangle of about 90 degrees or less relative to the general orientation ofthe non-thermoplastic embryonic fibers being extruded. The driedembryonic fibrous elements 30 can be collected on a collection device,such as a movable foraminous belt, patterned collection belt, or flatbelt. The addition of a vacuum source directly under the formation zonemay be used to aid collection of the fibers.

II. Process for Manufacturing a Water Soluble Product

The various water soluble fibrous plies disclosed herein can be used tomanufacture water soluble products 5. The process for manufacturing canbe performed on discrete plies of material. Discrete plies of materialare individual pieces of the various plies described herein that areassembled and joined in some manner to form a single water solubleproduct 5. Optionally, the process for manufacturing can be performed oncontinuous ply webs described herein that are assembled and joined insome manner and are cut to form multiple water soluble products 5.

The process of manufacturing a water soluble product 5 can comprise thefollowing steps as illustrated in FIG. 4. A water soluble first ply 10can be provided. A water soluble second ply 15 can be provided separatefrom the first ply 10. The first ply 10 and the second ply 15 aresuperposed with one another. By superposed it is meant that one ispositioned above or below the other with the proviso that additionalplies or other materials, for example active agents, may be positionedbetween the superposed plies. A portion of the first ply 10 can bejoined to a portion of the second ply 15 to form the water solubleproduct 5. Importantly, the second ply 15 can be formed on a surface 52other than the first ply 10. That is second ply 15 is optionally notformed on the first ply 10 as might occur if a plurality of fibrouselements 30 are discharged from a first die block assembly 40 onto abelt 50 to form a first ply 10 of material and then another plurality offibrous elements 30 is discharged from a second die block assembly 40 ontop of the first ply 10 to form a second ply 15 on top of the first ply10.

Each ply may comprise one or more layers. A ply formed of multiplelayers can have coherency amongst two or more of the layers to form anintegral ply. There can be intermingling of fibers constituting layersof a ply and intermingling of fibers between plies that are next to oneanother.

The second ply 15 can be cut from the first ply 10, in which case thesecond ply 15 and first ply 10 can be formed on the same forming surfaceand be integral with one another at the time and location of formation.It might be advantageous to not form one ply on top of another becausesuch a construction will have one surface that is a belt side having atexture that might differ from the air side of the of such construction.That can make it difficult to print on both sides of the product 5,result in one side being more prone to leak particles as compared toanother side if particles are provided in or on a layer, and result in aproduct 5 that has one side that differs in surface texture or hand thanthe other, which can be confusing to a consumer as be or she may thinkthat the different sides of the product 5 may have a different function.

By joined it is meant that the elements are attached or connecteddirectly to one another or are attached or connected to one anotherindirectly through one or more intermediate elements that are attachedor connected to the element being referred to as joined.

More practically, the first ply 10 can be provided as part of a firstcontinuous ply web 60 and the second ply 15 can be provided as part of asecond continuous ply web 65, by way of non-limiting example as shown inFIG. 5. FIG. 5 is a nonlimiting example of how a two-ply product 5 canbe formed. First continuous ply web 60 and the second continuous ply web65 can be superposed to superpose what ultimately becomes the first ply10 and the second ply 15 in a product 5. At this stage of the process,what ultimately becomes the individual water soluble products 5 can bepart of a continuous multi-ply webs. There can be intermingling offibers constituting the plies. This may occur when the plies forming theproduct 5 are brought into contact with one another and or bonded to oneanother.

It can be practical to spin a first continuous ply web 60 having a widthfrom about 20 cm to about 500 cm, or from about 20 cm to about 100 cm,or from about 20 cm to about 80 cm, or from about 40 cm to about 70 cm,or about 60 cm. Such a first continuous ply web 60 can be cut in themachine direction MD to form multiple plies that can be stacked form oneor more products 5 in on or more lanes of product 5 production. Forinstance, it can be practical to provide a first continuous ply web 60that is about 60 cm wide and cut it into three continuous plies eachhaving a width of about 20 cm, stack those three continuous plies, jointhose three plies together, to form two or more products 5 in the crossdirection CD.

In FIG. 5, product 5 making reduces down to a single lane with thepotential for making multiple products 5 in the cross direction.Optionally, there can be multiple product making lanes fed by a wide webformed from a wide die assembly 40. The wide web can be slit in themachine direction to form a plurality of first continuous ply webs 60and second continuous ply webs 65 so that multiple lanes of productmaking are possible. For example, a duplicate of the apparatus shown inFIG. 5 could be positioned immediately next to the apparatus shown inFIG. 5 but a single die assembly 40 could feed a wide continuous ply webinto the individual lanes of product making, with the cutting knife 70configured to separate out the continuous ply webs as appropriate tofeed the individual lanes of product 5 making.

After the step of superposing the first ply 10 and second ply 15, thesuperposed first continuous ply web 60 and second continuous ply web 65can be joined to one another and cut to form the water soluble product5. A first portion 11 of the first ply 10 can be joined to a secondportion 16 of the second ply 15 to the water soluble product 5.

The first continuous ply web 60 can be provided separately from thesecond continuous ply web 65. For instance, the first continuous ply web60 can be formed using a die block assembly 40 that is separate from thedie block assembly 40 used to make the second continuous ply web 65.Optionally the first continuous ply web 60 and second continuous ply web65 can be supplied as separate parent rolls of such materials. It can bepractical to employ a continuous process from formation of the plies tofinished product 5 because it can be challenging to handle and storewater soluble fibrous webs.

The second continuous ply web 65 can be cut from the first continuousply web 60. For instance, the first continuous ply web 60 can be formedon a die block assembly 40 and then cut in the machine direction MD by aknife 70, as shown in FIG. 5, for instance a rotary cutting knife thatcuts in the machine direction MD. Cutting ply webs from the firstcontinuous ply web 60 can be practical for providing bettermanufacturing quality control since only a single die block assemblymust be controlled and control ends up being universally applied to eachply web. This contrasts to the situation in which one die block is usedto form one ply and another die block is used to form another ply andboth die blocks must be carefully monitored and controlled. Also, suchan arrangement can be helpful for minimizing trimming waste that mightbe required for edges of the ply web which may be thinner than portionsof the ply web nearer to the centerline of the ply web in the machinedirection MD. Thin edges of the plies can result in the need to processand handle plies and products 5 that have a nonuniform caliper, forinstance by trimming edges having reduced caliper or paying carefulattention to the orientation in which plies are superposed to form aproduct 5.

The process can further comprise a step of positioning the first plybelt side 75 and the second ply belt side 80 to face away from oneanother prior to joining the first ply 10 and the second ply 15. Thiscan be accomplished by providing only a single 180 degree twist in thesecond continuous ply web 65. The first ply belt side 75 is the side ofthe first ply 10 that was formed in contact with a surface 52 or belt50. In FIG. 5, the second continuous ply web 65 is twisted 90 degreestwice so that the second ply air side 85 faces away from the first plybelt side 75. One or both of the first continuous ply web 60 and secondcontinuous ply web 65 can be twisted 0 degrees, which could be twistedand untwisted by the same number of degrees, 180 degrees (for exampleright hand or left hand twist of 180 degrees, optionally in two 90degree steps) or 360 degrees prior to bringing the first continuous plyweb 60 and second continuous ply web 65 into facing relationship toobtain the desired positioning of the first ply belt side 75, first plyair said 90, second ply belt side 80, and second ply air side 85,relative to one another. It can be practical for the first ply air side90 (or first continuous ply web air side) and second ply air side 85 (orsecond continuous ply web air side) to be in contact with one anotherand for the first ply belt side 75 (or first continuous ply web beltside) and second ply belt side 80 (or second continuous ply web beltside) to be facing away from one another with the first ply air side 90and the second ply air side 85 (or second continuous ply web air side)between the first ply belt side 75 (or first continuous ply web beltside) and the second ply belt side 80 (or second continuous ply web beltside). Such an arrangement can position the belt side of the plies orcontinuous ply webs to face outwardly and ultimately form the exteriorsurface of the product 5 which can provide for a better tactile feel andor a surface upon which printing is convenient. Further, if multilayerplies or continuous ply webs are employed and particles are provided inone of the layers of the multilayer plies the belt side can act as abarrier to contain the particles and separate the consumer's hand fromthe particles.

If a step of the process further comprises a step of positioning thefirst ply belt side 75 and the second ply belt side 80 to face away fromone another prior to joining the first ply 10 and the second ply 15,such step can occur by twisting one of the first continuous ply web 60or second continuous ply web 65 180 degrees and placing the firstcontinuous ply web 60 and second continuous ply web 65 in facingrelationship with one another. The twisting of a continuous ply web canbe performed by lifting the continuous ply web from the belt 50,twisting the continuous ply web 180 or 360 degrees, and placing thecontinuous ply web that was twisted to be in facing relationship withthe other continuous ply web.

Twisting can be facilitated by lifting the continuous ply web with oneor more, or a system of, turning bars 77. For instance, a turning bar 77can be placed proximal the belt 50 and the continuous ply web can be fedaround the turning bar 77 upwards. The continuous ply web can be twistedthe desired amount and fed onto an elevated turning bar 77. Thecontinuous ply web can be moved in the cross direction CD to bepositioned above the other continuous ply web and fed over anotherturning bar 77. Then the continuous ply web can be fed downward and overanother turning bar 77 proximal the belt 50 to be in facing relationshipwith the other continuous ply web. Other ways known in the art forflipping a continuous web can be employed, such as a contoured invertingsurface.

The turning bars 77 may be static polished metal turning bars 77 or maybe turning bars 77 that rotate about an axis driven by a motor or thedrag force of the continuous ply web passing the turning bars 77, suchas a roller. The turning bars 77 may be polished metal turning bars 77to permit the continuous ply web to slide over the turning bars 77 withinconsequential drag force from the turning bars 77 so that thecontinuous ply web is not stretched more than is tolerable.

The first continuous ply web 10 can be considered to have a first plybelt side 75 and a first ply air side 90 opposite the first ply beltside 75. Similarly, the second continuous ply web 65 can be consideredto have a second ply belt side 80 and a second ply air side 85 oppositethe second ply belt side 80.

The belt side and air side of the plies can have a difference in surfacetexture. The belt side of a ply or continuous ply web is the side of theply or continuous ply web that was formed in contact with the belt 50upon which the fibrous elements 30 were deposited. That is, the beltside of a ply or continuous ply web can be the side of ply or continuousply web facing and in contact with the belt 50 upon which fibrouselements 30 were deposited. The belt side can tend to have a flattersurface profile than the air side since the fibrous elements 30 mayconform or partially conform to the surface 52 of the belt 50 on whichthe fibrous elements 30 land. The air side has no constraining surface.Absent post deposition processing, the air side of the plies may tend tobe fluffier or loftier, possibly less coherent, than the belt side.Providing products 5 that have the belt sides of the plies facingoutwardly can be practical for presenting the smoother surfaces of theplies outwardly for subsequent printing, better tactile feel and look,and better ability to contain particles. Also, if multilayer plies areprovided, plies containing particles can confined to the interior of theproduct 5 so that the user does not have or has limited contact with theparticles, which may comprise active agents.

One or more of the plies may be provided with particles comprising oneor more active agents, by way of nonlimiting example as shown in FIG. 6.For instance, the first ply 10 can be provided with a first plurality 91of water soluble first particles 95. Similarly, the second ply 15 can beprovided with a second plurality 100 of water soluble second particles105. The first particles 95 can be compositionally the same as thesecond particles 105. This might be convenient if the second ply 15 iscut from the first ply 10, by way of nonlimiting example as shown inFIG. 5, without regard to the twisting and superposing steps downstreamof knife 70.

Optionally, the outer surfaces of the product 5 can comprise the beltside surfaces of the plies. For instance, the first ply belt side 75 andthe second ply belt side 80 can positioned to face away from one anotherprior to joining the first ply 10 and second ply 15. Describedotherwise, the first ply air side 90 and the second ply air side 85 canface towards one another prior to joining the first ply 10 and secondply 15. Possible benefits to such a construction are discussedpreviously.

The process of manufacturing described herein may be convenientlyemployed fabricate products 5 having multiple plies and optionallymultilayer plies. Multiple plies and multilayer plies enable themanufacturer to provide for different product benefits in each ply orlayer, active agents away from the layers forming the outer surface ofthe products 5, surfaces that are convenient to print upon, and products5 that are pleasant to touch.

The process of manufacturing described herein can further comprise thesteps of providing a fibrous first layer 20 and providing a fibroussecond layer 25 facing, or in facing relationship with, the fibrousfirst layer 20. There can be intermingling of fibers constituting thefirst layer 10 and fibers constituting the second layer 25. As shown inFIG. 7, the first ply 10 can comprise a fibrous first layer 20 and afibrous second layer 25. The first layer 20 and the second layer 25 cantogether form the first ply 10. The second layer 25 and the first layer20 can be in facing and contacting relationship with one another, forinstance as would occur if the second layer 25 is deposited on the firstlayer 20. The second layer 25 can comprise a first plurality 91 of watersoluble first particles 95 distributed within the second layer 25. Theprocess of manufacturing described herein can further comprise the stepsof providing a fibrous third layer 110 and providing a fibrous fourthlayer 115 facing, or in facing relationship with, the fibrous thirdlayer. The third layer 110 and the fourth layer 115 can be in facing andcontacting relationship with one another, for instance as would occur ifthe fourth layer 115 is deposited on the third layer 110.

The second ply 15 can comprise the fibrous third layer 110 and thefibrous fourth layer 115. The third layer 110 and the fourth layer 115can together form the second ply 15. The fourth layer 115 can comprise asecond plurality 100 of water soluble second particles 105 distributedwithin the fourth layer 115. Providing multilayer plies can tend toenhance the stiffness of the product 5. Further multilayer plies enablethe product designer to place active agents in chosen layers of theplies, optionally provide for different active agents in differentlayers of the plies, and optionally place active agents between thelayers and or plies.

Multilayer ply webs can be formed as illustrated in FIG. 3, by way ofnonlimiting example. Each ply web can be formed independently of othersby employing multiple die block assemblies 40. And optionally, firstparticles 95, second particles 105, and third particles can beintroduced as described herein.

Each of the third layer 110 and the first layer 20 can have a basisweight from about 20 gsm to about 500 gsm, optionally about 40 gsm toabout 100 gsm, optionally about 50 gsm to 80 gsm, according to the BasisWeight Test Method. Each of second layer 25 and the fourth layer 115 canhave a basis weight from about 20 gsm to about 500 gsm, optionally about40 gsm to about 300 gsm, optionally about 200 gsm, according to theBasis Weight Test Method.

Any embodiments contemplated herein, the first continuous ply web 60,second continuous ply web 65, and third continuous ply web 130 (ifpresent) can have a basis weight from about 100 gsm to about 800 gsm,optionally from about 150 gsm to about 500 gsm, optionally about 200 gsmto about 300 gsm, according to the Basis Weight Test Method.

To provide for products 5 having surfaces that are easy to print uponand are pleasant to touch, it can be practical to have the belt facingsurfaces of the plies forming the outer surface of the product 5. Asshown in FIG. 7, the first layer 20 can be oriented towards a first plybelt side 75 and the second layer 25 can be oriented towards a first plyair side 90. The first ply air side 90 can be opposite the first plybelt side 75. The third layer 110 can be oriented towards the second plybelt side 80 and the fourth layer 115 can be oriented towards a secondply air side 85. The second ply air side 85 can be opposite the secondply belt side 80. The process of manufacturing the product 5 cancomprise the further step of positioning the first ply belt side 75 andthe second ply belt side 80 to face away from one another prior tojoining the first ply 10 and the second ply 15. This arrangement canprovide a benefit of positioning the first particles 95 and secondparticles 105 towards the interior of the product 5 and remote frombeing in contact with the consumer's hand as the product is handled. Inthis arrangement, the second layer 25 and the fourth layer 115 can bebetween the first layer 20 and the third layer 110.

It can be practical to provide the first layer 20 to have fewer firstparticles 95 than the second layer 25 and a further the fifth layer ifpresent. The first layer 20 can be free of or substantially free offirst particles 95. Optionally the second layer 25 can be free of orsubstantially free of second particles 105. Similarly, the fifth layer,if present, can be free of or substantially free of third particles.Such an arrangement can be practical for minimizing consumer exposure tothe active agents in particles and or active agents that are in thefibrous elements 30 forming the second layer 25 and or fourth layer 115or any other layer that is interior to layers forming the surface of theproduct 5.

A three-ply product 5 can also be practical. A nonlimiting example ofthe process to make a three-ply product 5 is shown in FIG. 8. To make athree-ply product 5, the process further comprises the step of providinga water soluble fibrous third ply 120. The third ply 120 can be separatefrom the first ply 10 and second ply 15. The first ply 10, second ply15, and third ply 120 can be superposed with one another so that thethird ply 120 is between the first ply 10 and second ply 15. The firstply 10, second ply 15, and third ply 120 can be joined to form the watersoluble product 5.

The third ply 120 can be provided as part of a third continuous ply web130. Conveniently, the third continuous ply web 130 can be cut in themachine direction (MD) from the first continuous ply web 60. Forinstance, a first continuous ply web 60 can be provided by depositingfibrous elements 30 onto a belt 50. Optionally, particles can beintroduced into the stream of fibrous elements 30 between the die blockassembly 40 and the belt 50. Further optionally, particles can beintroduced onto the air side of the first continuous ply web 60. Thesecond continuous ply web 65 and the third continuous ply web 130 can becut from the first continuous ply web 60. A third continuous ply web 130is considered to be cut in the machine direction MD from the firstcontinuous ply web 60 if it is cut in the machine direction MD from thesecond continuous ply web 65 after the second continuous ply web 65 iscut in the machine direction MD from the first continuous ply web 60.

In one configuration of the process, three lanes 125 of separatecontinuous ply webs can be provided in the machine direction MD. Thelanes of continuous ply webs may be in any order in the cross directionand web handling appurtenances may be used to lift individual continuousply webs from the belt 50 and lay them onto another continuous ply webwith either the belt side or air side facing up. Starting with a singlecontinuous ply web such as the first continuous ply web 60 and cuttingfrom that ply web the second continuous ply web 65 and third continuousply web 130 can simplify manufacturing quality control since only asingle die block assembly 40 and optionally a particle providingapparatus need to be monitored and controlled. Optionally, each of thecontinuous ply webs can be formed by one or more separate die blockassemblies 40.

After superposing the first continuous ply web 60, second continuous plyweb 65, and third continuous ply web 130, such continuous ply webs canbe cut to form the water soluble product 5. Optionally, two or more ofsuch continuous ply webs can first be joined to one another and then cutto form the water soluble product 5. Optionally, the step of joining twoor more of the continuous ply webs and cutting such webs to form thewater soluble product 5 can be combined in a single step. Furtheroptionally, such continuous ply webs can be cut to provide the first ply10, second ply 15, and third ply 120, before joining two or more of suchplies to form the water soluble product 5.

Like the two ply water soluble product 5 discussed above and for thesame reasons as discussed above, when a third ply 120 is positionedbetween the first ply 10 and second ply 15 it can be practical for theprocess to further comprise the step of positioning the first ply beltside 75 and the second ply belt side 80 to face away from one anotherprior to joining portions of the first ply 10 and second ply 15.

The process can further comprise the step of placing on or in one ormore of the first ply 10, second ply 15, and third ply 120, and anylayer of such ply (e.g. first layer 20, second layer 25, third layer110, fourth layer 115, or any layer constituting the third ply 120) oneither or both the air side or belt side of such ply or continuous plyweb an active agent selected from the group consisting of unencapsulatedperfume, encapsulated perfume, surfactant, enzyme, bleach, chelant,structurant, builder, organic polymeric compound, brightener, hueingagent, suds suppressor, conditioning agent, humectant, alkalinitysystem, pH control system, buffer alkanolamine, insect repellant, haircare agent, hair conditioning agent, skin care agent, sunscreen agent,skin conditioning agent, fabric softener, anti-wrinkling agent,anti-static agent, fabric care stain removal agent, soil release agent,dispersing agent, suds suppressing agent, suds boosting agent, anti-foamagent, fabric refreshing agent, dishwashing agent, hard surface careagent, antimicrobial agent, antibacterial agent, antifungal agent,bleach activating agent, chelating agent, builder, lotion, air careagent, carpet care agent, dye transfer-inhibiting agent, clay soilremoving agent, anti-redeposition agent, polymeric soil release agent,polymeric dispersing agent, alkoxylated polyamine polymer, alkoxylatedpolycarboxylate polymer, amphilic graft copolymer, dissolution aid,buffering system, water-softening agent, water-hardening agent, pHadjusting agent, flocculating agent, effervescent agent, preservative,cosmetic agent, make-up removal agent, lathering agent, deposition aidagent, coacervate-forming agent, clay, thickening agent, latex, silica,drying agent, odor control agent, antiperspirant agent, cooling agent,warming agent, absorbent gel agent, anti-inflammatory agent, dye,pigment, acid, base, liquid treatment active agent, agricultural activeagent, industrial active agent, ingestible active agent, medicinalagent, teeth whitening agent, tooth care agent, mouthwash agent,periodontal gum care agent, dietary agent, vitamin, minerals,water-treatment agent, water clarifying agent, water disinfecting agent,and mixtures thereof. The active agent may be provided as particlesintroduced into the stream for fibrous elements 30 discharged from anyof the die block assemblies 40. The active agent may end up beingpositioned between plies of the product 5, embedded in one or more ofthe plies forming the product 5, or partially embedded in one or more ofthe plies forming the product 5.

During the process of manufacturing a product 5, the active agent may bedeposited on the upper facing surface 600 of any ply or in any ply, oron and in any ply, or on the air side 72 of any continuous ply web, orin any continuous ply web by an active agent applicator 135. One or moreactive agent applicators 135 can be provided on the manufacturing line140. An active agent applicator 135 can be a nozzle, extruder, sifter,printer, transfer roll, air atomized spray nozzle, hydraulicallyatomized spray nozzle, fluid applicator, extrusion applicator, hotmeltapplicator, ink jet, flexographic printer, gravure printer, offsetgravure, drop on demand ink jet, or any other device suitable fordepositing an active agent onto a ply, especially a moving ply. Activeagent applicators 135 can be positioned over any over any lane or any ofthe plies.

For reasons of practicality, active agents may be placed on or in or onand in the upwards facing side of any continuous ply web after thecontinuous ply web is positioned to have the desired side facing up. Ifan active agent is applied on or in or on and in a continuous ply webbefore the continuous ply web is finally placed in its vertical positionof the product 5, the active agent might contact the turning bars 77.That could result poor web handling if active agent residue accumulateson the turning bars 77. For instance, as shown in FIG. 8, the activeagent applicator 135 places active agent on the third continuous ply web130 after the third continuous ply web 130 is positioned on top of thefirst continuous ply web 60. After the active agent is placed on thethird continuous ply web 130, the second continuous ply web 65 can beplace on top of the third continuous ply web 130 so that the thirdcontinuous ply web 130 is between the first continuous ply web 60 andthe second continuous ply web 65.

Optionally, an active agent may be placed on or in the first ply airside 90, i.e. the upwards facing surface of the first continuous ply web60 before the third continuous ply web 130 is positioned on top of thefirst continuous ply web 60. As such, when a three ply product 5 isemployed, active agent can be conveniently provided above or below thethird ply 120, on or in the upper facing surface of either side of thethird ply 120, or on or in an inwardly oriented side of the first ply 10or second ply 10. So, for three ply product 5, multiple incompatibleactive agents can be conveniently separated from one another by thethird ply 120.

The process can further comprise the step of providing a solution offilament-forming composition 35. The filament-forming composition 35 canbe passed through one or more die block assemblies 40 comprising aplurality of spinnerets 45 to form a plurality of fibrous elements 30.The plurality of fibrous elements 30 can be deposited onto a belt 50moving in a machine direction MD to form the first ply 10. The first ply10 or first continuous ply web 60 can be cut in the machine direction toform the second ply 15, second continuous ply web 65, third ply 120, andor third continuous ply web 130, as described previously. Optionally,multiple filament-forming compositions may be supplied to a single dieblock assembly 40 or portions thereof or multiple filament-formingcompositions may be supplied to multiple die block assemblies 40.

The first particles 95 and second particles 105 can be introduced intothe stream of fibrous elements 30 before the fibrous elements 30 aredeposited onto a belt 50.

The process illustrated in FIG. 8 can be used to manufacture three plywater soluble products 5 in a continuous process. The continuous processcan be uninterrupted from the step of providing the filament formingcomposition 35 to formation of the water soluble products 5, whether thewater soluble products 5 exist as part of a web of a plurality of watersoluble products joined to one another or are discrete water solubleproducts separated from one another. A benefit of a continuous processis that the ply or continuous ply webs do not need to be stored beforeconverting such materials into water soluble products. Storage of pliesor continuous ply webs that are water soluble can require undueattention to temperature, humidity, and gentle handling to preserve theintegrity of such materials. By continuous process, it is meant that thesteps of the process occur in on a continuous manufacturing line.

At the upstream end of the process, a filament forming composition 35can be provided. The filament forming composition can passed through adie block assembly 40 comprising a plurality of spinnerets 45 to form aplurality of fibrous elements 30. The fibrous elements 30 can bedeposited on a belt 50 moving in a machine direction to form a firstlayer 20. The first layer 20 can then pass beneath another die blockassembly 40 from which a filament forming composition 35 is exitingthrough a plurality of spinnerets 45 to form a plurality of fibrouselements 30. Particles can be inserted into the stream of fibrouselements 30. The fibrous elements 30 and particles can be laid on top ofthe first layer 20 in a second layer 25. Together, the first layer 20and second layer 25 can form the first ply 10 which can be part of thefirst continuous ply web 60.

The first ply 10 can be cut in the machine direction MD into three lanes125 of plies. The center lane can be the first continuous ply web 60.The outer lanes 125 can be the second continuous ply web 65 and thirdcontinuous ply web 130, of which the second ply 15 and third ply 120 canbe part of, respectively. One or more active agent applicators 135 canapply one or more active agents to the second layer 25.

An optional third ply 120 as part of a third continuous ply web 130 canbe lifted from the belt 50 and placed onto the first ply 10 that can bepart of a first continuous ply web 60. Optionally, the third ply 120 orthird continuous ply web 130 can be inverted before placement upon thefirst ply 10 or first continuous ply web 60. Optionally, one or moreactive agent applicators 135 can apply one or more active agents to theair side of third ply 120 or third continuous ply web 130.

A second ply 15 as part of a second continuous ply web 65 can be liftedfrom the belt 50 and placed on top of the third ply 120 or thirdcontinuous ply web 130, if present, or in the absence thereof, on top ofthe first ply 10 or first continuous ply web 60. Optionally, the secondply 15 or second continuous ply web 65 can be inverted before placementupon the third ply 120 or third continuous ply web 130, if present, orin the absence thereof, on top of the first ply 10 or first continuousply web 60.

As shown in FIG. 8, the turning bars 77 can be provided at a first webhandling station 78 and a second web handling station 79. The first webhandling station 78 can be downstream of the die block assembly 40 andupstream of the second web handling station 79. The active agentapplicator or applicators 135 can be positioned upstream of the firstweb handling station 78 and or between the first web handling station 78and the second web handling station 79. The active agent applicator 135can be positioned upstream of the first web handling station 79 andpositioned to overlie the first continuous ply web 60. Optionally, theactive agent applicator 135 can be positioned between the first webhandling station 78 and the second web handling station 79 so that itoverlies the third continuous ply web 130, the first continuous ply web60 incidentally being beneath the third continuous ply web 130.Positioning the active applicator or applicators 135 as such permits theactive agent to be positioned towards the interior of the finishedproduct 5, reducing the potential for the consumer to contact the activeagent.

The water soluble products 5 can be printed upon by one or more printingunits 150. A printing unit 150 can be positioned anywhere on themanufacturing line so that the desired surface of one or more of thefirst ply 10, second ply 15, and or third ply 120 can be printed upon.The printing can be CMYK printing. The printing can be laser jet, inkjet, gravure, pad, rotogravure, flexographic, offset, screen,lithographic, or any other printing approach suitable for printing websof material, particularly process that are best suited for nonwovenmaterials. A drier 220 can be located downstream or upstream of theprinting unit 150.

The first ply 10 and second ply 15, or a first portion 11 of the firstply 10 and a second portion 16 of a second ply 15, can be joined to oneanother, for instance by using a bonding roll, to form the water solubleproduct 5. If there is a third ply 120 between the first ply 10 and thesecond ply 15, the third ply 120 can be contained within the first ply10 and second ply 15. Optionally, the first ply 10 and second ply 15 canbe joined to the third ply 120 so that the first ply 10 and second ply15 are joined to one another through the third ply 120.

Plies can be bonded to one another by thermal bonding. Thermal bondingcan be practical if the plies contain thermoplastic powder, optionallywater soluble thermoplastic material. Thermal bonding can also bepractical if the fibers constituting the plies are thermoplastic. Pliescan optionally be calendar bonded, point bonded, ultrasonically bonded,infrared bonded, through air bonded, needle punched, hydroentangled,melt bonded, adhesive bonded, or other known technical approach forbonding plies of material.

The water soluble products 5 can be separated from one another by a diecutter 160, optionally a rotary die cutter 160. A rotary die cutter 160comprises a die roll and an anvil roll, the die roll and anvil rotatingcounter to one another. The plies can be bonded to one another and diecut in a single step using a single reciprocating bonding and diecutting apparatus or a rotary bonding and die cutting apparatus. In arotary bonding and die cutting apparatus that combines the bonding anddie cutting, the die is shaped to provide a die cut in which thematerial being cut is pinched between the knife-edge of the die and thesmooth surface of the anvil. Further the die is shaped to compressportions of the plies, or continuous ply webs, and layers thereoftogether to bond the plies, continuous ply webs, and layers thereof toone another. The die can be a patterned die that provides a cutting andbonding pattern to the plies, continuous ply webs, and layers thereof.Optionally, the die can be heated, which might be practical for thermalbonding of the plies, continuous ply webs, and layers thereof.

A three ply water soluble product 5 is shown in FIG. 9. Each of theplies can be a multi-layer ply.

There can be intermingling of fibers of one layer with fibers of anotherlayer next thereto. There can also be intermingling of fibers of one plywith fibers of another layer or ply next thereto. As shown in FIG. 9,the third ply 120 can be between the first ply 10 and second ply 15. Thethird ply 120 can be a single layer ply or a multi-layer ply. The thirdply 120 can have a third ply belt side 165 and third ply air side 170opposite the third ply belt side 165. The third ply 120 can comprise afibrous fifth layer 175 and a fibrous sixth layer 180. The fifth layer175 and the sixth layer 180 together forming the third ply 120.Optionally, the third ply 120 can comprise a plurality of thirdparticles 185. Further optionally, the sixth layer 180 can comprisethird particles 185. One or more active agents 190 can be between thethird ply 120 and the second ply 15. The third ply 120 can optionally beflipped relative to that shown in FIG. 9 with sixth layer 165 orientedtowards the second layer 25. Likewise, the plies can be arranged in anydesired order in any desired orientation.

There can be any integer number greater than or equal to two of plies ina product 5. That may be accomplished by providing such number of pliesor continuous ply webs and stacking such plies or continuous ply webs,inverting any of the plies or continuous ply webs as desired, andassembling such plies or continuous ply webs to for such products 5.

The processes disclosed here can be performed in a controlledenvironment. The processes can be performed in an environment in whichthe relative humidity is from about 15% to about 85%, optionally fromabout 30% to about 60%, optionally about 45%, and a temperature fromabout 15° C. to about 40° C., optionally about 15° C. to about 30° C.,optionally about 18° C. to about 25° C., and any combination of theaforesaid ranges or values of relative humidity and temperature. Withoutbeing bound by theory, these ranges of relative humidity and temperatureare thought to provide conditions in which plies can be manufactured andconverted into finished products.

Diameter Test Method

The diameter of a discrete fibrous element or a fibrous element within afibrous structure is determined by using a Scanning Electron Microscope(SEM) or an Optical Microscope and an image analysis software. Amagnification of 200 to 10,000 times is chosen such that the fibrouselements are suitably enlarged for measurement. When using the SEM, thesamples are sputtered with gold or a palladium compound to avoidelectric charging and vibrations of the fibrous element in the electronbeam. A manual procedure for determining the fibrous element diametersis used from the image (on monitor screen) taken with the SEM or theoptical microscope. Using a mouse and a cursor tool, the edge of arandomly selected fibrous element is sought and then measured across itswidth (i.e., perpendicular to fibrous element direction at that point)to the other edge of the fibrous element. A scaled and calibrated imageanalysis tool provides the scaling to get actual reading in mu m. Forfibrous elements within a fibrous structure, several fibrous elementsare randomly selected across the sample of the fibrous structure usingthe SEM or the optical microscope. At least two portions of the fibrousstructure are cut and tested in this manner. Altogether at least 100such measurements are made and then all data are recorded forstatistical analysis. The recorded data are used to calculate average(mean) of the fibrous element diameters, standard deviation of thefibrous element diameters, and median of the fibrous element diameters.Another useful statistic is the calculation of the amount of thepopulation of fibrous elements that is below a certain upper limit. Todetermine this statistic, the software is programmed to count how manyresults of the fibrous element diameters are below an upper limit andthat count (divided by total number of data and multiplied by 100%) isreported in percent as percent below the upper limit, such as percentbelow 1 micrometer diameter or Geo-submicron, for example. We denote themeasured diameter (in pm) of an individual circular fibrous element asd_(i).

In the case that the fibrous elements have non-circular cross-sections,the measurement of the fibrous element diameter is determined as and setequal to the hydraulic diameter which is four times the cross-sectionalarea of the fibrous element divided by the perimeter of thecross-section of the fibrous element (outer perimeter in case of hollowfibrous elements). The number-average diameter, alternatively averagediameter is calculated as:

$d_{num} = \frac{\sum_{i = 1}^{n}d_{i}}{n}$

Shear Viscosity Test Method

The shear viscosity of a filament-forming composition of the presentinvention is measured using a capillary rheometer, Goettfert Rheograph6000, manufactured by Goettfert USA of Rock Hill S.C., USA. Themeasurements are conducted using a capillary die having a diameter D of1.0 mm and a length L of 30 mm (i.e., L/30). The die is attached to thelower end of the rheometers 20 mm barrel, which is held at a die testtemperature of 75 deg. C. A preheated to die test temperature, 60 gsample of the filament-forming composition is loaded into the barrelsection of the rheometer. Rid the sample of any entrapped air. Push thesample from the barrel through the capillary die at a set of chosenrates 1,000-10,000 seconds⁻¹. An apparent shear viscosity can becalculated with the rheometer's software from the pressure drop thesample experiences as it goes from the barrel through the capillary dieand the flow rate of the sample through the capillary die. The log(apparent shear viscosity) can be plotted against log (shear rate) andthe plot can be fitted by the power law, according to the formula:

η=Kγ ^(n−1)

wherein η is the apparent shear viscosity, K is the material's viscosityconstant, n is the material's thinning index and γ is the shear rate.The reported apparent shear viscosity of the filament-formingcomposition herein is calculated from an interpolation to a shear rateof 3,000 sec⁻¹ using the power law relation.

Basis Weight Test Method

Basis weight of a fibrous structure is measured on stacks of twelveusable units using a top loading analytical balance with a resolution of+−0.001. g. The balance is protected from air drafts and otherdisturbances using a draft shield. A precision cutting die, measuring8.890 cm+−0.0089 cm by 8.890 cm +−0.0089 cm is used to prepare allsamples. With a precision cutting die, cut the samples into squares.Combine the cut squares to form a stack twelve samples thick. Measurethe mass of the sample stack and record the result to the nearest 0.001g.

-   The Basis Weight is calculated in g/m2 as follows:-   Basis Weight=(Mass of stack)/[(Area of 1 square in stack)*(No. of    squares in stack)]-   For example,-   Basis Weight(g/m²)=Mass of stack (g)/[79.032 (cm²)/10,000    (cm²/m²)*12]-   Report result to the nearest 0.1 g/m². Sample dimensions can be    changed or varied using a similar precision cutter as mentioned    above, so as that there are at least 645.16 cm² of sample area in    stack and the basis weight calculation is adjusted accordingly.

Thickness Test Method

Thickness of a fibrous structure is measured by cutting 5 samples of afibrous structure sample such that each cut sample is larger in sizethan a load foot loading surface of a VIR Electronic Thickness TesterModel II available from Thwing-Albert Instrument Company, Philadelphia,Pa. Typically, the load foot loading surface has a circular surface areaof about 20.258 cm². The sample is confined between a horizontal flatsurface and the load foot loading surface. The load foot loading surfaceapplies a confining pressure to the sample of 15.5 g/cm². The thicknessof each sample is the resulting gap between the flat surface and theload foot loading surface. The thickness is calculated as the averagethickness of the five samples. The result is reported in millimetersmm).

Examples and Combinations

An example follows:

-   -   A. A process for manufacturing a water soluble product (5)        comprising the steps of: providing a water soluble fibrous first        ply (10); providing a water soluble fibrous second ply (15)        formed on a surface (52) other than said first ply, wherein said        second ply is separate from said first ply; superposing said        first ply and said second ply; and joining a first portion (11)        of said first ply to a second portion (16) of said second ply to        form said water soluble product.    -   B. The process according to Paragraph A, further comprising the        steps of: providing said first ply as part of a first continuous        ply web (60); providing said second ply as part of a second        continuous ply web (65); and cutting said first continuous ply        web and second continuous ply web after the step of superposing        said first ply and said second ply to form said water soluble        product.    -   C. The process according to Paragraph B, further comprising the        step of cutting in a machine direction (MD) said second        continuous ply web from said first continuous ply web.    -   D. The process according to any of Paragraphs A to C, wherein        said first ply has a first ply belt side (75) and a first ply        air side (90) opposite said first ply belt side; wherein said        second ply has a second ply belt side (80) and a second ply air        side (85) opposite said second ply belt side; and    -    wherein said process further comprises a step of positioning        said first ply belt side and said second ply belt side to face        away from one another prior to joining said first ply and said        second ply.    -   E. The process according to any of Paragraphs A to D, further        comprising the steps of: providing said first ply with a first        plurality of water soluble first particles (95); and providing        said second ply with a second plurality of water soluble second        particles (105).    -   F. The process according to any of Paragraphs A to E, further        comprising the steps of: providing a fibrous first layer (20);    -    providing a fibrous second layer (25) facing said fibrous first        layer, said second layer comprising a first plurality of water        soluble first particles (95) distributed within said second        layer, said first layer and said second layer together forming        said first ply; providing a fibrous third layer (110);    -    providing a fibrous fourth layer (115) facing said fibrous        third layer, said fourth layer comprising a second plurality of        water soluble second particles (105) distributed within said        fourth layer, said third layer and said fourth layer together        forming said second ply.    -   G. The process according to Paragraph F, wherein said first        layer is oriented towards a first ply belt side (75) and said        second layer is oriented towards a first ply air side (90),        wherein said first ply air side is opposite said first ply belt        side, wherein said third layer is oriented towards a second ply        belt side (80) and said fourth layer is oriented towards a        second ply air side (85), wherein said second ply air side is        opposite said second ply belt side, wherein said process further        comprises the step of positioning said first ply belt side and        said second ply belt side to face away from one another prior to        joining said first ply and said second ply.    -   H. The process according to Paragraph F or G, wherein said first        layer contains fewer first particles than said second layer and        said third layer contains fewer second particles than said        fourth layer.    -   I. The process according to Paragraphs F to H, wherein said        process comprises the step of placing on or in one or both of        said second layer and said fourth layer an active agent selected        from the group consisting of unencapsulated perfume,        encapsulated perfume, perfume premix, surfactant, enzyme,        bleach, bleach activator, chelant, structurant, builder, organic        polymeric compound, brightener, hueing agent, suds suppressor,        conditioning agent, humectant, alkalinity system, pH control        system, buffer alkanolamine, insect repellant, hair care agent,        hair conditioning agent, skin care agent, sunscreen agent, skin        conditioning agent, fabric softener, anti-wrinkling agent,        anti-static agent, fabric care stain removal agent, soil release        agent, dispersing agent, suds suppressing agent, suds boosting        agent, anti-foam agent, fabric refreshing agent, dishwashing        agent, hard surface care agent, antimicrobial agent,        antibacterial agent, antifungal agent, bleach activating agent,        chelating agent, builder, lotion, air care agent, carpet care        agent, dye transfer-inhibiting agent, clay soil removing agent,        anti-redeposition agent, polymeric soil release agent, polymeric        dispersing agent, alkoxylated polyamine polymer, alkoxylated        polycarboxylate polymer, amphilic graft copolymer, dissolution        aid, buffering system, water-softening agent, water-hardening        agent, pH adjusting agent, flocculating agent, effervescent        agent, preservative, cosmetic agent, make-up removal agent,        lathering agent, deposition aid agent, coacervate-forming agent,        clay, thickening agent, latex, silica, drying agent, odor        control agent, antiperspirant agent, cooling agent, warming        agent, absorbent gel agent, anti-inflammatory agent, dye, hueing        agent, pigment, acid, base, liquid treatment active agent,        agricultural active agent, industrial active agent, ingestible        active agent, medicinal agent, sleep aid, teeth whitening agent,        tooth care agent, mouthwash agent, periodontal gum care agent,        dietary agent, vitamin, minerals, water-treatment agent, water        clarifying agent, water disinfecting agent, and mixtures        thereof.    -   J. The process according to any of Paragraphs A to I, further        comprising the steps of: providing a water soluble fibrous third        ply (120) separate from said first ply and said second ply,        wherein said third ply is formed on a surface other than said        first ply or said second ply;    -    superposing said first ply, said second ply, and said third ply        with one another so that said third ply is between said first        ply and said second ply;    -    joining portions of said first ply and said second ply to form        said water soluble product.    -   K. The process according to Paragraph J, wherein said first ply        is provided as part of a first continuous ply web and said        second ply is provided as part of a second continuous ply web,        wherein said third ply is provided as part of a third continuous        ply web, wherein said first continuous ply web, said second        continuous ply web, and said third continuous ply web are cut to        form said water soluble product after the step of superposing        said first ply, said second ply, and said third ply with one        another.    -   L. The process according to Paragraph J or K, wherein said        process comprises the step of placing on or in said third ply or        said second layer or said fourth layer an active agent selected        from the group consisting of unencapsulated perfume, perfume        premix, encapsulated perfume, surfactant, enzyme, bleach, bleach        activator, chelant, structurant, builder, organic polymeric        compound, brightener, hueing agent, suds suppressor,        conditioning agent, humectant, alkalinity system, pH control        system, buffer alkanolamine, insect repellant, hair care agent,        hair conditioning agent, skin care agent, sunscreen agent, skin        conditioning agent, fabric softener, anti-wrinkling agent,        anti-static agent, fabric care stain removal agent, soil release        agent, dispersing agent, suds suppressing agent, suds boosting        agent, anti-foam agent, fabric refreshing agent, dishwashing        agent, hard surface care agent, antimicrobial agent,        antibacterial agent, antifungal agent, bleach activating agent,        chelating agent, builder, lotion, air care agent, carpet care        agent, dye transfer-inhibiting agent, clay soil removing agent,        anti-redeposition agent, polymeric soil release agent, polymeric        dispersing agent, alkoxylated polyamine polymer, alkoxylated        polycarboxylate polymer, amphilic graft copolymer, dissolution        aid, buffering system, water-softening agent, water-hardening        agent, pH adjusting agent, flocculating agent, effervescent        agent, preservative, cosmetic agent, make-up removal agent,        lathering agent, deposition aid agent, coacervate-forming agent,        clay, thickening agent, latex, silica, drying agent, odor        control agent, antiperspirant agent, cooling agent, warming        agent, absorbent gel agent, anti-inflammatory agent, dye, hueing        agent, pigment, acid, base, liquid treatment active agent,        agricultural active agent, industrial active agent, ingestible        active agent, medicinal agent, sleep aid, teeth whitening agent,        tooth care agent, mouthwash agent, periodontal gum care agent,        dietary agent, vitamin, minerals, water-treatment agent, water        clarifying agent, water disinfecting agent, and mixtures        thereof.    -   M. The process according to any of Paragraphs J to L, wherein        said second ply and said third ply are cut in a machine        direction from said first ply.    -   N. The process according to any of Paragraphs A to M, further        comprising the steps of: providing solution of filament-forming        composition (35);    -    passing said filament forming composition through one or more        die block assemblies (40) comprising a plurality of spinnerets        (45) to form a plurality of fibrous elements (30);    -    depositing said plurality of fibrous elements onto a belt (50)        moving in a machine direction (MD) to form said first ply;    -    cutting said first ply in said machine direction to form said        second ply; and cutting said first ply and said second ply to        form said water soluble product after the step of superposing        said first ply and said second ply;    -    wherein said process is a continuous process.    -   O. The process according to Paragraph N, further comprising the        step of introducing said plurality of first particles and said        plurality of second particles into a stream of said plurality of        fibrous elements before the step of depositing said plurality of        fibrous elements onto said belt.    -   P. The process according to any of Paragraphs A to 0, further        comprising the step of printing on one or more of said first ply        and said second ply.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A process for manufacturing a water soluble product comprising thesteps of: providing a water soluble fibrous first ply; providing a watersoluble fibrous second ply formed on a surface other than said firstply, wherein said second ply is separate from said first ply;superposing said first ply and said second ply; and joining a firstportion of said first ply to a second portion of said second ply to formsaid water soluble product; wherein said first ply has a first ply beltside and a first ply air side opposite said first ply belt side; whereinsaid second ply has a second ply belt side and a second ply air sideopposite said second ply belt side; and wherein said process furthercomprises a step of positioning said first ply belt side and said secondply belt side to face away from one another prior to joining said firstply and said second ply.
 2. The process according to claim 1 furthercomprising the steps of: providing said first ply as part of a firstcontinuous ply web; providing said second ply as part of a secondcontinuous ply web; and cutting said first continuous ply web and secondcontinuous ply web after the step of superposing said first ply and saidsecond ply to form said water soluble product.
 3. The process accordingto claim 2, further comprising the step of cutting in a machinedirection said second continuous ply web from said first continuous plyweb.
 4. (canceled)
 5. The process according to claim 1 furthercomprising the steps of: providing said first ply with a first pluralityof water soluble first particles; and providing said second ply with asecond plurality of water soluble second particles.
 6. The processaccording to claim 1 further comprising the steps of: providing afibrous first layer; providing a fibrous second layer facing saidfibrous first layer, said second layer comprising a first plurality ofwater soluble first particles distributed within said second layer, saidfirst layer and said second layer together forming said first ply;providing a fibrous third layer; and providing a fibrous fourth layerfacing said fibrous third layer, said fourth layer comprising a secondplurality of water soluble second particles distributed within saidfourth layer, said third layer and said fourth layer together formingsaid second ply.
 7. The process according to claim 6, wherein said firstlayer is oriented towards said first ply belt side and said second layeris oriented towards said first ply air side, wherein said third layer isoriented towards said second ply belt side and said fourth layer isoriented towards said second ply air side, wherein said process furthercomprises the step of positioning said first ply belt side and saidsecond ply belt side to face away from one another prior to joining saidfirst ply and said second ply.
 8. The process according to claim 7,wherein said process comprises the step of placing on or in one or bothof said second layer and said fourth layer an active agent selected fromthe group consisting of unencapsulated perfume, encapsulated perfume,perfume premix, surfactant, enzyme, bleach, bleach activator, chelant,structurant, builder, organic polymeric compound, brightener, hueingagent, suds suppressor, conditioning agent, humectant, alkalinitysystem, pH control system, buffer alkanolamine, insect repellant, haircare agent, hair conditioning agent, skin care agent, sunscreen agent,skin conditioning agent, fabric softener, anti-wrinkling agent,anti-static agent, fabric care stain removal agent, soil release agent,dispersing agent, suds suppressing agent, suds boosting agent, anti-foamagent, fabric refreshing agent, dishwashing agent, hard surface careagent, antimicrobial agent, antibacterial agent, antifungal agent,bleach activating agent, chelating agent, builder, lotion, air careagent, carpet care agent, dye transfer-inhibiting agent, clay soilremoving agent, anti-redeposition agent, polymeric soil release agent,polymeric dispersing agent, alkoxylated polyamine polymer, alkoxylatedpolycarboxylate polymer, amphilic graft copolymer, dissolution aid,buffering system, water-softening agent, water-hardening agent, pHadjusting agent, flocculating agent, effervescent agent, preservative,cosmetic agent, make-up removal agent, lathering agent, deposition aidagent, coacervate-forming agent, clay, thickening agent, latex, silica,drying agent, odor control agent, antiperspirant agent, cooling agent,warming agent, absorbent gel agent, anti-inflammatory agent, dye, hueingagent, pigment, acid, base, liquid treatment active agent, agriculturalactive agent, industrial active agent, ingestible active agent,medicinal agent, sleep aid, teeth whitening agent, tooth care agent,mouthwash agent, periodontal gum care agent, dietary agent, vitamin,minerals, water-treatment agent, water clarifying agent, waterdisinfecting agent, and mixtures thereof.
 9. The process according toclaim 7, further comprising the steps of: providing said first ply aspart of a first continuous ply web; cutting in a machine direction asecond continuous ply web from said first continuous ply web said secondply being part of said second continuous ply web; and cutting said firstcontinuous ply web and said second continuous ply web after the step ofsuperposing said first ply and said second ply to form said watersoluble product.
 10. The process according to claim 1, furthercomprising the steps of: providing a water soluble fibrous third plyseparate from said first ply and said second ply, wherein said third plyis formed on a surface other than said first ply or said second ply;superposing said first ply, said second ply, and said third ply with oneanother so that said third ply is between said first ply and said secondply; joining portions of said first ply and said second ply to form saidwater soluble product.
 11. The process according to claim 10, whereinsaid first ply is provided as part of a first continuous ply web andsaid second ply is provided as part of a second continuous ply web,wherein said third ply is provided as part of a third continuous plyweb, wherein said first continuous ply web, said second continuous plyweb, and said third continuous ply web are cut to form said watersoluble product after the step of superposing said first ply, saidsecond ply, and said third ply with one another.
 12. (canceled)
 13. Theprocess according to claim 1, wherein said process comprises the step ofplacing on or in said third ply or said first ply air side or saidsecond ply air side an active agent selected from the group consistingof unencapsulated perfume, encapsulated perfume, perfume premix,surfactant, enzyme, bleach, bleach activator, chelant, structurant,builder, organic polymeric compound, brightener, hueing agent, sudssuppressor, conditioning agent, humectant, alkalinity system, pH controlsystem, buffer alkanolamine, insect repellant, hair care agent, hairconditioning agent, skin care agent, sunscreen agent, skin conditioningagent, fabric softener, anti-wrinkling agent, anti-static agent, fabriccare stain removal agent, soil release agent, dispersing agent, sudssuppressing agent, suds boosting agent, anti-foam agent, fabricrefreshing agent, dishwashing agent, hard surface care agent,antimicrobial agent, antibacterial agent, antifungal agent, bleachactivating agent, chelating agent, builder, lotion, air care agent,carpet care agent, dye transfer-inhibiting agent, clay soil removingagent, anti-redeposition agent, polymeric soil release agent, polymericdispersing agent, alkoxylated polyamine polymer, alkoxylatedpolycarboxylate polymer, amphilic graft copolymer, dissolution aid,buffering system, water-softening agent, water-hardening agent, pHadjusting agent, flocculating agent, effervescent agent, preservative,cosmetic agent, make-up removal agent, lathering agent, deposition aidagent, coacervate-forming agent, clay, thickening agent, latex, silica,drying agent, odor control agent, antiperspirant agent, cooling agent,warming agent, absorbent gel agent, anti-inflammatory agent, dye, hueingagent, pigment, acid, base, liquid treatment active agent, agriculturalactive agent, industrial active agent, ingestible active agent,medicinal agent, sleep aid, teeth whitening agent, tooth care agent,mouthwash agent, periodontal gum care agent, dietary agent, vitamin,minerals, water-treatment agent, water clarifying agent, waterdisinfecting agent, and mixtures thereof.
 14. The process according toclaim 13, wherein said second ply and said third ply are cut in amachine direction from said first ply.
 15. The process according toclaim 1 further comprising the steps of: providing a solution offilament-forming composition; passing said filament forming compositionthrough one or more die block assemblies comprising a plurality ofspinnerets to form a plurality of fibrous elements; depositing saidplurality of fibrous elements onto a belt moving in a machine directionto form said first ply; cutting said first ply in said machine directionto form said second ply; and cutting said first ply and said second plyto form said water soluble product after the step of superposing saidfirst ply and said second ply; and wherein said process is a continuousprocess.
 16. The process according to claim 15, wherein said first plycomprises a fibrous first layer and a fibrous second layer, said firstlayer and said second layer together at least partially forming saidfirst ply, wherein said second layer comprises a first plurality ofwater soluble first particles distributed within said second layer, andwherein said second ply comprises a fibrous third layer and a fibrousfourth layer, said third layer and said fourth layer together formingsaid second ply, wherein said fourth layer comprises a second pluralityof water soluble second particles distributed within said fourth layer.17. The process according to claim 16, wherein said first layer isoriented towards said first ply belt side and said second layer isoriented towards said first ply air side, wherein said third layer isoriented towards said second ply belt side and said fourth layer isoriented towards said second ply air side.
 18. The process according toclaim 16, further comprising the step of introducing said plurality offirst particles and said plurality of second particles into a stream ofsaid plurality of fibrous elements before the step of depositing saidplurality of fibrous elements onto said belt.
 19. The process accordingto claim 15, further comprising the steps of: providing a water solublefibrous third ply separate from said first ply and said second ply;cutting said third ply from one of said first ply and said second ply;superposing said first ply, said second ply, and said third ply with oneanother so that said third ply is between said first ply and said secondply; and cutting said third ply as part of the step of cutting saidfirst ply and said second ply to form said water soluble product. 20.The process according to claim 15, further comprising the step ofprinting on one or more of said first ply and said second ply.